Support garment or tape and method of making the same

ABSTRACT

A method of producing a variable compression garment. The method includes: identifying, in a base textile having a first elongation and memory characteristic, a first region having a second elongation and memory characteristic; applying to the base textile, in the first region, a first layer of an elastomer; drying the first layer of the elastomer to adhere the first layer of the elastomer to the base textile; applying to the base textile, in the first region, at least a second layer of the elastomer; drying the second layer of the elastomer to adhere the second layer of the elastomer to the first layer on the base textile; and baking the first and second layers of the elastomer to cure the first and second layers of the elastomer.

FIELD OF THE INVENTION

The present invention relates to a compression garment. Moreparticularly, although not exclusively, the present invention relates toa compression support garment arranged to be used in sports and jointsupport by providing a variable compression to corresponding body part.The invention also relates to support tapes and methods of makingsupport garments and tapes.

BACKGROUND TO THE INVENTION

In our daily lives, many activities pose a heavy burden on our musclesand joints. Examples include sports and exercises such as jogging andcycling, standing and walking, as well as carrying and lifting heavyitems for a prolonged period. These physical exertions can causefatigue, and in excess can lead to damage of muscles and joints.

There are a range of products available to support muscles and jointsduring exercise or daily activities, including compression garments,sleeves, support braces and tapes. A common feature in such products isan elastic element or characteristic that holds one or more musclesand/or joints firmly in place and/or is designed to stretch with andsupport muscles and joints as they move. The aim of such products is toprevent injury, improve athletic performance, and/or aid healing orrecovery.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided amethod of producing a variable compression garment or tape, including:applying to a base textile having a first elongation and memorycharacteristic, in a first region of the base textile, a first layer ofan elastomer; drying the first layer of the elastomer to adhere it tothe base textile; applying to the base textile in the first region atleast a second layer of the elastomer; drying the second layer of theelastomer to adhere it to the first layer or the base textile; andbaking the first and second layers of elastomer to cure the first andsecond layers of elastomer. The method preferably also includeidentifying, in the base textile, the first region to have a desiredsecond elongation and memory characteristic. The method may additionallyor alternatively include providing the base textile prior to theidentification step.

The method may also include: determining a number of layers of theelastomer to provide the second elongation and memory characteristic;and after the drying of the second layer of the elastomer, applying anadditional number of layers of elastomer and drying each additionallayer before applying a next additional layer.

The method may also include: determining a desired direction and/orgradient of the second elongation and memory characteristic; determininga pattern or patterns for the first, second, and optionally theadditional, layers of the elastomer to provide the desired directionand/or gradient; and applying the first, second, and optionally theadditional, layers of the elastomer includes applying the layers in thedetermined pattern or patterns. Preferably, the desired direction and/orgradient include two or more directions or gradients. The pattern orpatterns may include one or more of: a pattern of interlocking shapes, apattern of parallel lines and/or a pattern of one or more crossinglines.

The method may also include: identifying a second region of the basetextile to have a desired third elongation and memory characteristic;determining a number of layers of elastomer to provide the thirdelongation and memory characteristic; and before the baking step,applying to the base textile in the second region one or moresecond-region-layers of the elastomer, and drying eachsecond-region-layer before applying a next second-region-layer.

The method may also include: determining a desired direction and/orgradient of the third elongation and memory characteristic; determininga second-region-pattern or -patterns for the one or moresecond-region-layers of the elastomer; and applying the one or moresecond-region-layers of the elastomer may include applying thesecond-region-layers in the determined second-region-pattern or-patterns.

Preferably, the baking step comprising baking for at least 4 hours, andmore preferably at least 8 hours, at a temperature of between 70 and 90degrees centigrade.

Preferably, the elastomer is silicon or polymer baser elastomer.

In one embodiment, applying the layers or the second-region-layers ofthe elastomer includes printing the layers, preferably using a capillaryfilm screen printing method.

Preferably, drying the layers or the second-region-layers of theelastomer comprises flash drying the layers at 140 degrees centigradefor at least 6 seconds.

The method may also include: before applying the layers or thesecond-region-layers of the elastomer, applying a base layer of a primermaterial to the base textile and drying the primer layer.

One or more patterns or second-region-pattern or -patterns may include3D patterns for providing the determined desired direction and/orgradient of the second and third elongation and memory characteristics.

Preferably, the material of the base textile includes at least 80% ofcotton and/or polyester and/or nylon.

The method may also include: prior to applying to the base textile inthe first region a first layer of an elastomer, cutting the base textileto form a panel of a compression garment.

The method may also include: prior to applying to the base textile inthe first region a first layer of an elastomer, cutting the base textileform a panel of a compression garment and joining the base textile panelwith additional panels to form the compression garment.

The method may also include: after the baking step, cutting the textileform a panel of a compression garment, wherein the panel includes atleast one of the first or second regions, and joining the panel withadditional panels to form the compression garment.

The method may also include: prior to applying to the base textile inthe first region a first layer of an elastomer, cutting the base textileto form a panel of a compression garment, and joining the panel withadditional panels to form the compression garment.

In a preferred embodiment of the first aspect, the variable compressiongarment is any one of: a shirt, shorts, tights, sleeves, socks,underwear, or a joint brace or support.

In a preferred embodiment of the first aspect, the variable compressiongarment comprises a medical support garment, the medical support garmentincludes any one of: a joint brace, a knee support, a calf support, anankle support, a shoulder support, an elbow support, an arm support, awrist support or a hand and/or figure support.

In accordance with a second aspect of the invention, there is provided avariable compression garment or tape produced using the method of thefirst aspect. The variable compression garment can be, e.g., a shirt,shorts, tights, sleeves, socks, underwear, or a joint brace or support;or a medical support garment such as a joint brace, a knee support, acalf support, an ankle support, a shoulder support, an elbow support, anarm support, a wrist support or a hand and/or figure support.

In accordance with a third aspect of the invention, there is providedmeans for applying to a base textile having a first elongation andmemory characteristic, in a first region of the base textile, a firstlayer of an elastomer; means for drying the first layer of the elastomerto adhere it to the base textile; means for applying to the base textilein the first region at least a second layer of the elastomer; means fordrying the second layer of the elastomer to adhere it to the first layeror the base textile; and means for baking the first and second layers ofelastomer to cure the first and second layers of elastomer.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described, by way ofexample, with reference to the accompanying drawings in which:

FIG. 1 is a front view of a compression vest made according to theinvention,

FIG. 2 is a rear view of a compression vest made according to theinvention,

FIG. 3 is a front view of a compression leggings made according to theinvention,

FIG. 4 is a rear view of a compression leggings made according to theinvention,

FIG. 5 is a side view of a compression leggings made according to theinvention,

FIG. 6 is a front view of a compression shorts made according to theinvention,

FIG. 7 is a rear view of a compression shorts made according to theinvention,

FIG. 8 is a side view of a compression shorts made according to theinvention,

FIG. 9 is a rear and side view of a brace or support made according tothe invention,

FIG. 10 is a rear and side view of a back brace or support madeaccording to the invention,

FIG. 11 is a view of a knee brace or support made according to theinvention,

FIG. 12 is a view of an arm brace or support made according to theinvention,

FIG. 13 is a view of an elbow brace or support made according to theinvention,

FIG. 14 is a view of an ankle brace or support made according to theinvention,

FIG. 15 is a view of a wrist brace or support made according to theinvention,

FIG. 16 is an illustration of a multi-directional support and/orcompression pattern according to the invention,

FIG. 17 is a second illustration of a directional support and/orcompression pattern support pattern according to the invention, and

FIG. 18 is a schematic illustration of a method of making a supportgarment or tape in one embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Unless the context requires otherwise, the term compression garmentincludes a joint or muscle brace or support which might only providecompression or support to a joint or portion of a limb or torso of aperson.

Referring to FIGS. 1 and 2, there is shown a first embodiment of thepresent invention in the form of a compression garment 10 arranged toprovide at least a localized compression effect to a region or body partof a wearer. The compression garment 10 is a shirt, but may in otherembodiments be pants or shorts. The compression shirt 10 comprises abase textile 11 consisting of sleeve panels, a front panel 12 and a rearpanel 13 sewn or otherwise joined in a known manner. The base textile ofthe short has a first elongation and memory characteristic. The firstelongation and memory characteristic of the base textile 11 is achievedthrough the use in the textile of a combination of fibres, filamentsand/or yarns having different elasticity characteristics such as cotton,polyester, nylon, and various high elasticity fibres generally referredto as SPANDEX, LYCRA, Elastane and their variants. Preferably, the basetextile 11 comprises up to 95% cotton, polyester or nylon fibres, withthe remaining fibres being SPANDEX, LYCRA or a variant thereof. Thefirst elongation of the base textile 11 may be in any direction. In onesetting, it may elongate along a vertical direction. In other settings,it may elongate along a horizontal direction or a slanting/diagonaldirection. The base textile 11 further includes a memory characteristic,which allows the base textile to return substantially to its originalform before elongation.

The compression shirt 10 further comprises one or more regions 14, 15with an elongation characteristic different than that of the basetextile. The elastomer material is applied to, for example, a firstregion 14 on the base textile to give the first regions a desired secondelongation and memory characteristic different to the elongationcharacteristic of the base material. The first region 14 is a region forproviding a localized compression effect to the wearer, and varies frompositions depending on the different targeted body part. In thisexample, the first region 14 is the whole chest area on the shirt. Oneor more layer of an elastomer is applied and adhered to the base textile11 in the first region in a pattern such that the first region has adesired second elongation. Preferably, the second elongation is shorterthan the first elongation, for providing the greater localizedcompression effect. It further has a memory for substantially returningthe first region 14 to its original form before elongation.

The one of more layers of elastomer may take different patterns, shapes,and/or forms for providing the desired elongation characteristic. Thepattern may be a strip, intersecting lines, a network pattern or anycombination of these. Different shapes and forms may be used accordingto the targeted body part, in order to provide an optimum effect. InFIGS. 1 and 2, the elastomer at the chest region takes a form of apattern of interlocking shapes having an even elongation in orthogonaldirections. Referring to FIG. 16, specifically, the pattern ofinterlocking shapes is a knuckle lock pattern, which comprises a networkof hourglass or dumbbell shapes, distributed uniformly across the chestregion. The hourglass or dumbbell shape is closely packed with oneanother, with the two circular ends 31, 32 of each one fitted in theconcave part of another. The knuckle lock pattern can elongate alongfour directions—vertical, horizontal, 45° and −45° from the vertical.This pattern is advantageous in that it can provide stabilization ofchest muscle groups by preventing it from being stretched in randomdirections and lateral support through the sides.

The compression shirt 10 may further comprise a second region 15 on thebase textile 11 having a third elongation and memory characteristic.Similar to the first region, the second region 15 may be positioned at adifferent location depending on the targeted body part. In thisembodiment, the second region 15 may be located at the tricep and biceparea of the upper arm. One or more layer of elastomer is applied andadhered to the base textile 11 in a second pattern, illustrated in FIG.17, different to that of the first region 14, to provide a differentelongation pattern. Within the same region, the number of layers mayvary. For example, a first line in the region includes two layers ofelastomer and a second line may include three layers of elastomer. Theresulting cross-over part of the first and second line has five layersof elastomer.

FIG. 17 shows an enlarged view of the second region 15 of thecompression shirt 10 of FIGS. 1 and 2. The second region comprises across lock pattern 42 of one or more crossing lines and is formed bycontouring the elastomer. Specifically, a pattern of two groups of threeparallel lines 44 are contoured and progressed to a crossed-over patternto form a power up zone 40, the cross lock zone 42, and a lateralsupport zone. The power up zone 40 covers the triceps; the cross lockzone 42 covers right above the elbows for containing and supporting themuscles and joint. Additionally, a third region may be identified, and across lock pattern 15 is provided to support the waist muscles.

Referring to FIGS. 3 to 5, there is shown a pair of compression leggingsor tights 20 in one embodiment. Similar to the compression shirt 10, thecompression tights 20 comprises a base textile 16 and at least onecompression region having a different elongation from the base textile,for providing a localized compression effect. Regions are identified anddifferent patterns are chosen based on the targeted muscle group orjoint. For example, a high compression force may be desired for theextremities where main muscles groups and joints are located, and alower compression force for the core muscles or muscles groups near thecore.

Specifically, the compression tights 20 includes four compressionregions comprising two cross lock patterns 15 on each leg portion. Afirst cross lock pattern 15 is positioned at the anterior thigh musclesand a second cross lock pattern 15 is positioned at the calf muscles.Since the thighs and calves are the main muscle groups in the legs, thecross lock pattern 15 can confine and support individual muscle groupsand minimize the chance of muscle tearing. The heavy load exerts on theknees can be alleviated through the lateral support of the cross lockzone. The compression force exerted by the cross lock pattern 15 at theanterior thigh muscles may be different from or the same as compressionforce exerted by the cross lock pattern 15 at the calf muscles. Thehigher compression force can be achieved by applying additional layersof elastomer.

The compression tights 20 further comprises a knuckle lock pattern 14covering the hip and posterior thigh region. In this embodiment, theknuckle lock pattern 14 provides an optimum stabilization of hamstringand gluteus muscles by confining the compression region to be stretchedin four directions.

Referring to FIGS. 6 to 8 there is shown a pair of compression shorts 21in one embodiment. In this embodiment, the compression shorts 21 is athigh or knee-length shorts. Similar to the compression tights, thecompression shorts 21 includes a base textile, a cross lock pattern atthe anterior thigh on each leg and a knuckle lock pattern at the hip andposterior thigh.

Whilst the above description provide specific examples of thecompression garments, it should be noted that the invention can alsoapply to other types of garments, wearable, clothing (causal orsportswear), or any part of such garment, wearable, or clothing (causalor sportswear). For example, the compression garment may be a pair oftights, a pair of shorts, a sleeve, a sock, underwear, a joint brace orsupport, or a sports support tape.

Referring to FIGS. 9 to 15, there is shown a medical support garment inone embodiment. In this embodiment, the medical support garment is anarm support. In other embodiments, the medical support garment may be anelbow support, a knee support, a calf support, an ankle support, ashoulder support, a wrist support, or a hand and/or figure support. Thearm support in FIG. 12 comprises a base textile having one of morepatterns of regions with a different elongation characteristic.Preferably, the base textile is made of neoprene providing a firstcompression force to a targeted joints and/or muscle groups. The armsupport further comprises one or more layers of elastomer for providingan additional, localized compression force. The elastomer layer may be astrip, intersecting lines contoured to compress and support the targetedjoints and/or muscles.

FIG. 9 shows a back support in one embodiment of the invention worn onthe back. The back support is in the form of a loop, and it is made of abase material that is elastic and includes memory characteristic.Preferably, the base material is, for example neoprene. Multiple layersof base materials may be used or connected together. Elastic strip lines50 having a second elastic and memory characteristic are bonded,attached, or otherwise connected to the base material. Preferably, thestrip lines include elongate portions and cross portions. In thisembodiment, the strip lines generally extend around the loop, along thetop and bottom edges, and with axial crossings. Preferably, thecrossings are provided on the sides that correspond to the back and tothe side of the waist. The pattern may be substantially symmetric aboutthe centerline of the base material.

FIG. 10 shows a calf support in one embodiment of the invention. Theconstruction of the calf support is similar to that of back support inFIG. 10, except that the calf support only includes one layer of basematerial, and strip lines on the side of the support that corresponds tothe calf. The strip lines 50 generally extend axially on the basematerial, with multiple crossings between the top and bottom edges ofthe base material.

FIG. 11 shows a knee support in one embodiment of the invention. Theconstruction of the knee support is similar to that of calf support inFIG. 10, except that the pattern of the strip lines 50 is arrangeddifferently to provide support for the knee. In this embodiment,crossings of the strip lines are provided on the sides of the knee.

FIGS. 12, 13, 14, and 15 respectively show an arm support, an elbowsupport, a foot support, and a wrist support. They are of likeconstruction to the supports in FIGS. 9-11, except that they are shapedand sized to fit the corresponding body part, and have different stripline patterns.

Whilst the above description provide specific examples of thecompression garments, it should be noted that the invention can alsoapply to other types of garments, wearable, clothing (causal orsportswear), or any part of such garment, wearable, or clothing (causalor sportswear). The base material may be other flexible material. Thebase material preferably provides a first elasticity (having anelongation and memory) and the strip lines provide a second elasticity.The first elasticity is preferably different to the second elasticity.The pattern of the strip lines shown is merely exemplary. The striplines can be different form, shape, width, etc., but preferably theyprovide cross portions that provide improved support and or compressionof the base material. The base material may be formed with one or moreopenings, preferably at the bending point, to reduce restriction andprovide more flexibility during movement. In yet one more embodimentsthe base material may be an elastic sports tape material with anadhesive for adhering to the skin of a user/wearer. The tape may haveapplied to it one or more regions of an elastomer to provide the tapewith regions having a second elongation characteristic.

A variable compression garment, brace or support as described above canbe made of a lower grade textile or fabric having an elongation belowthat which might otherwise be suitable for such purpose. For example, ina compression garment a lower cost textile comprising, say, up to 95%cotton, Polyester or nylon and less than, say 30% elastane or otherhighly elastic synthetic fibres such as SPANDEX or LYCRA, can be used.Typical textile combinations include, say, a textile comprising 72%nylon and 28% highly elastic synthetic fibres such as LYCRA with aweight of 210 grams, or a textile comprising 76% polyester and 24%highly elastic synthetic fibres such as SPANDEX with a weight of 200grams, or a textile comprising 92% polyester and 8% highly elasticsynthetic fibres such as SPANDEX with a weight of 190 grams.

In order to provide the textile, or regions of the textile correspondingwith a desired compression or support zone, with a suitable elongationand memory, the textile is printed with an elastomer having a highelasticity and resilience. In one embodiment a silicon based elastomeris used. In another embodiment a polymer formula elastomer may be used.Other printable high elasticity and resilient elastomers may be used.The choice of elastomer is based on the perdominent fibres of basematerial that may be chosen, for example cotton, polyester or nylon, andthe desired elasticity of the elastomer. The elastomer is applied to theidentified support regions of the textile in two or more layers using ascreen printing technique to build up layers of the elastomer in aparticular 3D pattern, such as those described previously, to controlboth the elongation and memory of the support region and the directionof support.

Printing of the textile with the 3D patterns of elastomer in supportregions can be done in a nested fashion where several regions of atextile sheet are printed before cutting garment panels from the textileand joining them to form a garment. Alternatively printing can be doneafter cutting the garment panels but before sewing the garment, or thecompleted garment can be printed. Another advantage of printing thegarment panels with elastomer to control elongation, memory anddirection of support of the support region is that it allows fewerpanels to be used to construct a garment or support brace/sleeve.Garments relying on the base textile for compression and support requirepanels to be cut with support regions and direction in mind. Differentfabrics must be used in regions requiring different degrees ofcompression and support. Different panels must be used where differentdirectional support is desired. The present method overcomes or at leastameliorates this requirement because compression, support anddirectional stability of the support regions is controlled by printingof the textile.

According to a method in one embodiment of the invention, one or moresupport regions of the textile are identified where the textile is to beprovided with an elongation and memory characteristic higher than thatof the base textile itself. As aforementioned, such regions can beidentified before or after cutting garments panels from the textile, orbefore or after garment constructions. After the support regions areidentified a pattern and a required number of layers of the elastomerare determined or identified that will provided the desired elongation,memory and directional support for each identified support region. Ascreen printing method is then used to print the identified pattern ontothe textile support region in two or more layers. In one embodiment thescreen printing may involve use of an emulsion coating method to applythe elastomer to the screens. Such a method, while effective, mayrequire more layers to be printed to achieve the desired elongationcharacteristic due to inconsistency in thickness of elastomer applied tothe screens. The output must also be continually tested to make sureelongation is inside a range of consistency. In a preferred embodiment acapillary film screen printing is used where the elastomer emulsion isapplied to the screen from a capillary film. Using a capillary film of,say, between 50 and 125 microns results in an exact and consistentemulsion thickness on the screen and as result more accurate results maybe achieved with fewer printed layers.

Referring to FIG. 18, the elastomer in the support regions is built upin layers, including a first, and perhaps optionally, step 50 ofapplying, via a print screen 52, a primer layer 53 to the target textile51 in the support region to encourage and enhance adhesion of theelastomer to the base textile. Following each printing step is a flashdrying step 54. The flash drying preferably includes introducing theprinted textile briefly into a drying tunnel at say 140 degreescentigrade, or thereabouts, for say 6 seconds, or thereabouts. Theelastomer pattern is then built up by screen printing successive layersof elastomer and flash drying each layer. Then, in step 55, a firstlayer 56 of elastomer is applied to the primer layer 55 using a screenprinting technique. The first layer 56 of elastomer is the subjected toa flash drying step 54′. Continuing the process a second layer 58 ofelastomer is applied to the first layer in a subsequent printing step57, followed by another flash drying step 54″ of the second layer 58.Further printing steps, each followed by a flash drying step, areundertaken until the necessary thickness and pattern of elastomer isapplied to the support region for the desired elongation characteristicto be achieved. In a final, and perhaps optional, printing step 59, atop coat 60 may be printed onto the elastomer to provide an aesthetic orprotective top layer. In a preferred embodiment, the top layer may be asuede for both aesthetic and comfort purposes. in step 61, the layersare then dried in a tunnel 62 at say 140 degrees centigrade, orthereabouts, for say 120 seconds, or thereabouts.

After the 3D layered printing and drying steps are completed the variouslayers of the compression and support patterns of elastomer are set orcured in a final step 63. This is preferably done by baking the printedtextile on an oven 62. This baking step greatly increases the durabilityand effectiveness of the elastomer. The baking requirement may varydepend upon the elastomer used, and is sufficient to fully set or curedthe elastomer. In an embodiment with a silicon based elastomer material,the textile or garments may be baked for 4 to 8 hours at 70 to 90degrees centigrade. The baking time may vary with temperature—at lowerbaking temperatures the baking time may increase, but the temperatureand time should not be so high and long so as to damage the textile. Inone embodiment, the curing step 63 is at 70 degrees for 8 hours; inanother embodiment, the curing step 63 is at 90 degrees for 4 hours. Inother methods according to the invention, highly stretchable and UVcurable elastomers can be used and the curing step may includesubjecting the printed elastomer pattern to UV curing.

The following summarizes the basic method for making a variablecompression garment in the embodiment described above from a lower gradebase textile or fabric having a first elongation and memory:

identify a first region of the base textile to have a desired secondelongation and memory characteristic,

apply to the textile in the first region a first layer of an elastomer,

dry the first layer of the elastomer to adhere it to the textile,

apply to the textile in the first region at least a second layer of theelastomer,

dry the second layer of the elastomer to adhere it to the first layer ortextile, and

cure the elastomer layers, e.g., by baking the elastomer layers to curethe layers.

A further step may include determining a number of layers of theelastomer to provide the second elongation and memory characteristic,and after drying the second layer of the elastomer, applying anadditional number of layers of elastomer and drying each additionallayer before applying a next additional layer.

Yet a further step may include determining a desired direction and/orgradient of the second elongation and memory characteristic; determininga pattern or patterns for the first, second, and optionally theadditional, layers of the elastomer to provide the desired directionand/or gradient; and wherein applying the first, second, and optionallythe additional, layers of the elastomer comprises applying the layers inthe determined pattern or patterns. The desired direction and/orgradient may comprise two or more directions or gradients. The patternor patterns comprise, but is/are not limited to one of the patternsdiscussed above with reference to the drawings, or shown in thedrawings.

Another step may include identifying a second region of the base textileto have a desired third elongation and memory characteristic;determining a number of layers of elastomer to provide the thirdelongation and memory characteristic; and before the curing step,applying to the textile in the second region one or moresecond-region-layers of the elastomer, and drying eachsecond-region-layer before applying a next second-region-layer.Optionally there may be a step of determining a desired direction and/orgradient of the third elongation and memory characteristic; determininga second-region-pattern or -patterns for the one or moresecond-region-layers of the elastomer; and wherein applying the one ormore second-region-layers of the elastomer comprises applying thesecond-region-layers in the determined second-region-pattern or-patterns.

Baking the elastomer layers may optionally comprise baking the layersfor at least 6 hours, and more preferably at least 8 hours, at atemperature of between 50 and 90 degrees centigrade.

Applying the layers or the second-region-layers of the elastomer maycomprise printing the layers.

Drying the layers or the second-region-layers of the elastomer maycomprise flashing drying the layers at 140 degrees centigrade.

Optionally, before applying the layers or the second-region-layers ofthe elastomer, firstly applying a base layer of a primer material to thetextile and drying the primer layer.

The one or more patterns or second-region-pattern or -patterns comprise3D patterns for providing the determined desired direction and/orgradient of the second and third elongation and memory characteristics.

Optionally, prior to applying to the textile in the first region a firstlayer of an elastomer, the textile is cut to form a panel of acompression garment. Or optionally, prior to applying to the textile inthe first region a first layer of an elastomer, the textile is cut toform a panel of a compression garment and the textile panel joined withadditional panels to form the compression garment. Or optionally, afterthe curing/baking step, the textile is cut to form a panel of acompression garment, wherein the panel includes at least one of thefirst or second regions, and the textile panel is joined with additionalpanels to form the compression garment. Or optionally, prior to applyingto the textile in the first region a first layer of an elastomer, thetextile is cut to form a panel of a compression garment and the textilepanel is joined with additional panels to form the compression garment.

The method is used to produce a compression garment including but notlimited to any one of a shirt, shorts, tights, sleeves, socks,underwear, or a joint brace or support.

The method is also used to produce a medical support garment, includingbut not limited to any one of a joint brace, a knee support, a calfsupport, an ankle support, a shoulder support, an elbow support, an armsupport, a wrist support or a hand and/or figure support.

The method is also used to produce a medical support garment, such as abrace or support, in which the textile is substituted with a syntheticrubber sheet such as neoprene and 3D printing regions of the syntheticrubber sheet is used to enhance and control directional elongation andmemory of regions of the medical support garment.

The method is also used to produce a medical support garment, such as abrace or support, in which the textile is predominately elastane orother highly elastic synthetic fibres such as SPANDEX or LYCRA, and 3Dprinting regions of the synthetic rubber sheet is used to enhance andcontrol directional elongation and memory of regions of the medicalsupport garment.

The invention also includes a joint or muscle support/brace, and inparticular a medical support or brace) made according to theaforementioned method. The invention also includes the aforementionedmethod used to make a compression garment and/or a joint support orbrace including a combination of a textile selected to have a lowelongation and memory characteristic, and a elastomer printed to regionsof the garment in a pattern selected to have a provide a elongation andmemory characteristic.

It will be appreciated by persons skilled in the art that numerousvariations and/or modifications may be made to the invention as shown inthe specific embodiments without departing from the spirit or scope ofthe invention as broadly described. The present embodiments are,therefore, to be considered in all respects as illustrative and notrestrictive.

Any reference to prior art contained herein is not to be taken as anadmission that the information is common general knowledge, unlessotherwise indicated.

1. A method of producing a variable compression garment, comprising:identifying, in a base textile having a first elongation and memorycharacteristic, a first region having a second elongation and memorycharacteristic, applying to the base textile, in the first region, afirst layer of an elastomer, drying the first layer of the elastomer toadhere the first layer of the elastomer to the base textile, applying tothe base textile, in the first region, at least a second layer of theelastomer, drying the second layer of the elastomer to adhere the secondlayer of the elastomer to the first layer of the elastomer on the basetextile, and baking the first and second layers of the elastomer to curethe first and second layers of the elastomer.
 2. The method of claim 1,further including: determining number of layers of the elastomer neededto provide the second elongation and memory characteristic, and afterdrying the second layer of the elastomer, applying an additional numberof layers of the elastomer and drying each additional layer of theelastomer before applying a next additional layer of the elastomer. 3.The method of claim 1, further including: determining a direction and/orgradient of the second elongation and memory characteristic, anddetermining at least one pattern for the first, second, and anyadditional, layers of the elastomer to provide the direction and/orgradient, wherein applying the first, second, and any additional, layersof the elastomer comprises applying the first, second and any additionallayers of the elastomer in the at least one pattern that has beendetermined.
 4. The method of claim 3, wherein the direction and/orgradient comprise at least two directions or gradients
 5. The method ofclaim 3, wherein the at least one pattern comprises at least one patternchosen from the group consisting of a pattern of interlocking shapes, apattern of parallel lines, and a pattern of crossing lines.
 6. Themethod of claim 2, further including: identifying a second region of thebase textile having a third elongation and memory characteristic,determining number of layers of the elastomer needed to provide thethird elongation and memory characteristic, and before the baking,applying to the base textile, in the second region, at least onesecond-region layer of the elastomer, and drying each second-regionlayer before applying a next second-region layer.
 7. The method of claim6, further including: determining a direction and/or gradient of thethird elongation and memory characteristic, and determining at least onesecond-region pattern for the at least one second-region layer of theelastomer, wherein applying the at least one second-region layer of theelastomer comprises applying the sat least one second-region layer inthe at least one second-region pattern that has been determined.
 8. Themethod of claim 1, wherein the baking comprises baking for at least 4hours at a temperature of between 70 and 90 degrees centigrade.
 9. Themethod of claim 1, wherein the elastomer is a silicone-based or anon-silicone-based polymer.
 10. The method of claim 6, wherein applyingthe first, second, and any additional layers of the elastomer, or the atleast one second-region layer of the elastomer comprises printing the atleast one second-region layer.
 11. The method of claim 10 whereinprinting comprises capillary film screen printing.
 12. The method ofclaim 6, wherein drying the first, second, and any additional layers ofthe elastomer, or the at least one second-region layer of the elastomercomprises flash drying at 140 degrees centigrade for at least 6 seconds.13. The method of claim 7, further comprising, before applying thefirst, second, and any additional layers of the elastomer, or the atleast one second-region layer of the elastomer, applying a base layer ofa primer material to the base textile and drying the primer layer. 14.The method of claim 7, wherein the at least one second-region patterncomprises a 3D pattern for providing the direction and/or gradient ofthe second and third elongation and memory characteristics that havebeen determined.
 15. The method of claim 1, wherein the base textilecomprises at least 80% of a material selected from the group consistingof f cotton, polyester, and nylon, and combinations thereof.
 16. Themethod of claim 1, further comprising, prior to applying to the basetextile in the first region, a first layer of an elastomer, cutting thebase textile to form a panel of a compression garment.
 17. The method ofclaim 1, further comprising, prior to applying to the base textile, inthe first region, a first layer of the elastomer, cutting the basetextile form a panel of the variable compression garment and joining thebase textile panel with additional panels to form the variablecompression garment.
 18. The method of claim 1, further comprising,after the baking, cutting the has textile form a panel of the variablecompression garment, wherein the panel includes at least one of thefirst and second regions, and joining the panel with additional panelsto form the variable compression garment.
 19. The method of claim 1,further comprising, prior to applying to the base textile, in the firstregion, the first layer of the elastomer, cutting the base textile toform a panel of the compression garment, and joining the panel withadditional panels to form the variable compression garment.
 20. Themethod of claim 19, wherein the variable compression garment is selectedfrom the group of garments consisting of a shirt, shorts, tights,sleeves, socks, underwear, a joint brace, and a support.
 21. The methodof claim 19, wherein the compression garment comprises a medical supportgarment including at least one of a joint brace, a knee support, a calfsupport, an ankle support, a shoulder support, an elbow support, an armsupport, a wrist support, a hand support, and a figure support.
 22. Avariable compression garment produced using the method of claim 1.